Modular building

ABSTRACT

A modular building is constructed of premanufactured panels interlocked by means of integral latching devices on a system of specially constructed columns and beams. The modular building is fireproof and rigid. A minimum number of non-integral fastening devices is needed.

[ 51 May 16, 1972 Jr. AttorneyCharles M. Hogan and lrwin P. GarfinkleKotrbaty.. Rafter...... Bates Olsen....... 1/1956 McClune 4/1967ABSTRACT A modular building is constructed of premanufactured panelsinterlocked by means of integral latching devices on a system 13 Claims,6 Drawing Figures References Cited Bretland James D. Slayden, Nashville,Tenn.

Avco Corporation, Nashville, Tenn.

Oct. 5, 1970 [51] lnt.Cl.....

Field ofSearch...................

UNITED STATES PATENTS United States Patent Slayden [54] MODULAR BUILDING[72] inventor:

[73] Assignee:

[22] Filed:

[21] Appl.No.:

PATENTEDMAY 16 I572 SHEET 1 OF 4 IN VENTOR JAMES D. SLAYDEN allvh TRNEYS.

PATENTEDMY 16 I972 SHEET 2 [IF 4 INVENTOR. f JAMES D. SLAYDEN BY W,

ATTO NEYS.

PAIEN TEBMAY 16 I972 SHEET 3 [1F 4 JAMES 0. SLAYDEN BY 7, W

PATENTEDMAY 16 1972 INVENTOP. JAMES D. SLAYDEN BY Wu W E -SP Gu m ATTONEYS.

MODULAR BUILDING SUMMARY OF THE INVENTION by means of pins on the beams.At the sides, the panels are locked by means of unique integralconnectors which prevent both lateral and transverse motion of thepanels.

OBJECTS OF THE INVENTION It is an object of this invention to provide amodular building comprising a self-supporting frame structure and aplurality of enclosing panels secured to the frame by means of integrallocking devices.

Another object of this invention is to provide means for rigidlyinterlocking two or more panels.

Still another object of this invention is to provide means for rigidlysecuring a first member to a second member, said means including aplurality of tabs projecting from the edge of one member, each of saidtabs projecting at an angle to the vertical and including a wedgingsurface, a circular slot in the edge of the other member, said slothaving a diameter equal to the length of said tab for receiving saidtab, the surface surrounding said slot being wedged by the tab, and thedirection of the angle of certain of said tabs being opposite to thedirection of the others.

For further objects and advantages of this invention, reference shouldbe made to the following detailed drawings in which:

FIG. 1 is a view of the overall frame structure of a modular building;

FIG. 2 is a section taken through the line 22 in FIG. 1 showing thedetails of construction of a column;

FIG. 3 is a section taken through the line 3-3 in FIG. 1 showing thedetail of the connection of an I-beam to a column;

FIG. 4 is a top view showing the arrangement of panels between twocolumns;

FIG. 5 is an enlarged view showing panels in place; and

FIG. 6 is a perspective view of a panel.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENT FIG. 1 shows the frame of amodular building constructed in accordance with this invention. Aplurality of concrete pillars 10 provide the foundation for the framewhich includes a plurality of horizontal I-beams l2. Upstanding pins 14,welded to the l-beams 12 at predetermined locations, serve to locate andsecure vertical columns 16. The frame structure includes a plurality ofhorizontal lower I-beams l8 and horizontal upper I-beams extendingbetween the columns 16 and secured thereto. The roof support is providedby means of l-beams 19, provided with downwardly directed pins 21contained within the ends of the columns 16.

The lower l-beams 18 are provided with a plurality of upwardly extendingpins 22 while the upper I-beams 20 are provided with a plurality ofdownwardly extending pins 24. As will be seen, the pins 22 and 24 areused for securing the upper and lower edges of the wall panels in place.1

The details of the columns 16 are shown in FIG. 4. Each column comprisesa cylindrical steel tube 26 which provides the basic structural supportof the column. The bottom end of tube 26 when in place on the I-beam 12receives the pin 14 and is held in place thereby. The top end of tube 26receives the pin 21 on the roof l-beam 19. The tube 26 is fireproofed bymeans of two overlapping layers of gypsum board 28 so that the crosssection of the column is square or rectangular. The gypsum board is thenenclosed by a sheet metal housing 30.

The lower I-beams 18 are secured to the I-beams 12 by means ofpower-driven nails, welding, rivets, or any suitable fastening means.The end of each upper l-beam 20 is secured to a tube 26 by means of ashort length of a quarter round section 25 cut from a tube of the samediameter. The section 25 is secured by welding at one end 27 to thel-beam 20 and secured at the other end to the tube 26 by means of apowerdriven nail 29.

Wall panels are secured to the sides 32 and 34 of the housing 30 whichis provided with flanges 36, 38 to form channels for receiving the endsof the wall panels. Each side 32 (see FIGS. 4 and 5) is provided withtabs 46 while circular slots 48 Y are provided on each side 34. As willbe seen, the panels are secured to the column between the flanges bymeans of corresponding slots and tabs.

All the panels are identical. Each consists of a sheet metal frame 50,the inner and outer surfaces of which are covered by wall boards 52 and54, respectively. The frame 50 consists of side members 56 and 58, a topmember 60, and a bottom member 62. The top and bottom members 60 and 62are provided with holes 64 and 66, respectively, for receiving the pins22 and 24 in the I-bearns 18 and 20.

The side member 56 is provided with tabs 68 which are identical to thetabs 46 in the column 16. The side member 58 is provided with circularslots 70 which are identical to the slots 48 in the columns 16. Thelength of the tabs is slightly less than the diameter of the circularslots so that when properly aligned, a tab can enter a correspondingcircular slot in an adjacent column or panel.

The plane of each tab 68 and 46 is at an angle with respect to thevertical. As shown in the drawing, one tab is set with an inwardlydirected angle while the next is set with an outwardly directed angle.In addition, each tab is provided with an angled undersurface 72. Aftera tab enters a slot, the angled undersurface 72 permits the entire panelto be lowered until it wedges the sheet metal surrounding the slot. Thiswedging prevents lateral movement of the panels. Moreover, since thetabs are alternately displaced inwardly and outwardly, the tabs lock theadjacent panels or columns so that transverse movement (inwardly andoutwardly) is not permitted.

The cross section of a portion of a wall is shown in FIG. 4. As seen inFIG. 4, two panels 50 are installed between two columns 16 by lockingthe'panels to a respective column and to one another. The connection ofthe two panels is waterproofed by means of a seal 74 consisting of innerand outer T- flanges 76 and 78, which together form channels forreceiving the ends of the panels. The T-flanges extend from the top ofthe panel to the bottom and are provided with holes 80 which are alignedwith the holes 70, the tabs 68 projecting through the holes 80 and 70 tolatch the panels together. Waterproof resilient pads 82 are insertedbetween the T-flanges 76 and 78.

The advantages from the invention result from the fact that the buildingis almost entirely premanufactured. That is, almost all of the parts,the panels, the beams, the seals and the locking devices are capable ofmass production techniques. In addition, the assembly is accomplishedwith locking devices that are integral with or preassembled on thepanels and beams, and a minimum of fastening devices is required. Thelocking devices are of such a nature that reasonable manufacturingtolerances are permitted, while at the same time, a sealed, rigidstructure is produced. The building can be fabricated and assembled tomeet the most rigid building codes.

ALTERNATIVES Many alternatives within the invention are available. Forexample, instead of securing the pins 14 to the horizontal lbeams 12,the pins could be mounted on steel strips which are then imbedded in andsupported by a concrete slab or foundafirst and second panels, each ofsaid panels including a rectangular frame constructed of interconnectedtop, bottom and side members of rigid sheet material, the opening insaid frame being closed by inner and outer panel sheets, one of thesides of said frame having a plurality of aligned vertically spacedlaterally projecting tabs, the other of the sides of said frame having alike plurality of similarly spaced circular tab-receiving slots;

said tab-receiving slots having a diameter larger than the length ofsaid tabs, the tabs in one of said panels being received in thetab-receiving slots of the other, said tabs having an angled slotproviding a wedging surface against the sheet material surrounding saidtab-receiving slot, alternate ones of said tabs being inclined inwardlyand outwardly.

2. The invention as defined in claim 1 and a seal between adjacentpanels, said seal including a resilient pad.

3. The invention as defined in claim 2 wherein said resilient pad ismounted on a T-flange, said pad being mounted on the leg of saidT-fiange, said leg being positioned in the butt joint between saidpanels, the head of said T-flange covering said joint.

4. The invention as defined in claim 3 wherein first and secondresilient pads are mounted on first and second T- flanges, one of saidT-flanges being positioned with its head covering the inner side of saidjoint, the head of the other of said T-flanges covering the outer sideof said joint.

5. A wall for a modular building construction comprising:

a panel including a frame constructed of interconnected top, bottom andside members of rigid sheet material, the opening in said frame beingclosed by inner and outer panel sheets, one of the sides of said framehaving a plurality of aligned vertically spaced laterally projectingtabs, the other of the sides of said frame having a like plurality ofsimilarly spaced circular tab-receiving slots;

first and second vertical columns for supporting said wall panel, saidcolumns being constructed of sheet material, one of said columns havinga plurality of tab-receiving slots for receiving the tabs on said oneside member, the other of said columns having a plurality of tabs, saidtabs being received in the slots in said other side member,

said tab-receiving slots having a diameter larger than the length ofsaid tab, said tab having an angled slot providing a wedging surfaceagainst the sheet material surrounding said tab-receiving slot,alternate ones of said tabs being inclined inwardly and outwardly.

6. The invention as defined in claim 5 wherein each of said columnscomprises a cylindrical tube enclosed by a plurality of intermediateflat layers of rigid fireproofing material and an outer layer of rigidsheet metal, said layers providing a square outer cross section.

7. The invention as defined in claim 6 and a lower horizontal supportfor said wall, said support having spaced upstanding cylindrical pins,said cylindrical pins projecting into said cylindrical tubes of saidcolumns for supporting and positioning the lower end of said column.

8. A wall for a modular building construction comprising:

a panel including a frame constructed of interconnected top, bottom andside members of rigid sheet material, the opening in said frame beingclosed by inner and outer panel sheets, said top and bottom members ofsaid frame each having a plurality of aligned laterally spacedpinreceiving holes, one of the sides of saidframe having a plurality ofaligned vertically spaced laterally projecting tabs, the other of thesides of said frame having a like plurality of similarly spaced circulartab-receiving slots;

a lower support for said wall, said lower support having a plurality ofupwardly extending pins projecting through said pin-receiving holes insaid bottom member;

an upper support for said wall, said upper support having a plurality ofdownwardly extending pins projecting into said pin-receiving holes insaid top member; and

first and secondcolumns constructed of sheet material, in-

terconnections between said columns and said lower and upper supports,one of said columns having a plurality of circular tab-receiving slotsfor receiving the tabs on said one side member, the other of saidcolumns having a plurality of tabs, said tabs being received in theslots in said other side member, said circular slots having a diameterlarger than the length of said tabs, said tabs having an angled slotproviding a wedging surface against the sheet material surrounding saidtab-receiving slot, alternate ones of said tabs being inclined inwardlyand outwardly.

9. The invention as defined in claim 8 wherein each of said columnscomprises a cylindrical tube enclosed by a plurality of intermediateflat layers of rigid fireproofing material and an outer layer of rigidsheet metal to provide a square outer cross section, said tabs andtab-receiving slots being located on said outer layers of respectivecolumns.

10. The invention as defined in claim 9, the interconnection betweeneach column and said lower support for said wall includes an upstandingcylindrical pin secured on said support, said cylindrical pin projectinginto the cylindrical tube of said column, each of said pins providing apredetermined position for each of said columns on said support.

11. The combination comprising:

two abutting sheet metal surfaces;

a plurality of spaced aligned tabs projecting from one of said surfaces;

a like plurality of tab-receiving circular slots in the other surface,said slots having a diameter greater than the length of said tab, saidtabs projecting through said slots, said tabs having an angled wedgingsurface providing a wedge between said tabs and the surface surroundingsaid slots, adjacent tabs being oppositely inclined whereby saidsurfaces are firmly interconnected.

12. A wall for a modular building construction comprising:

a panel including a frame constructed of interconnected top, bottom andside members of rigid sheet material, the opening in said frame beingclosed by inner and outer panel sheets, said top and bottom members ofsaid frame each having a plurality of aligned laterally spacedpinreceiving holes;

a lower support for said wall, said lower support having a plurality ofupwardly extending pins projecting through said pin-receiving holes insaid bottom member;

an upper support for said wall, said upper support having a plurality ofdownwardly extending pins projecting into said pin-receiving holes insaid top member;

first and second columns constructed of sheet material;

interconnections between said columns and said lower and upper supportsand between said columns and the sides of said frame,

each of said columns comprising a cylindrical tube enclosed by aplurality of intermediate flat layers of rigid fireproofing material andan outer layer of rigid sheet metal to provide a square outer crosssection, the interconnection between each column and said lower supportfor said wall comprising an upstanding cylindrical pin secured on saidsupport, said cylindrical pin projecting into the cylindrical tube ofsaid column, each of said pins providing a predetermined position foreach of said columns on said support, the interconnection between eachcolumn and the sides of said panel being between a side member of saidpanel and said outer layer.

13. A wall for a modular building construction comprising:

a panel including a frame constructed of interconnected top, bottom ands ide members of rigid sheet material, the opening in said frame beingclosed by inner and outer panel sheets, said top and bottom members ofsaid frame each having a plurality of aligned laterally spacedpinreceiving holes;

a lower support for said wall, said lower support having a plurality ofupwardly extending pins projecting through said pin-receiving holes insaid bottom member;

an upper support for said wall, said upper support having a plurality ofdownwardly extending pins projecting into said pin-receiving holes insaid top member;

first and second columns;

interconnections between said columns and said lower and 5 uppersupports and between said columns and the sides of said frame,

each of said columns having a square outer cross section,

1. A wall for a modular building construction comprising: first andsecond panels, each of said panels including a rectangular frameconstructed of interconnected top, bottom and side members of rigidsheet material, the opening in said frame being closed by inner andouter panel sheets, one of the sides of said frame having a plurality ofaligned vertically spaced laterally projecting tabs, the other of thesides of said frame having a like plurality of similarly spaced circulartabreceiving slots; said tab-receiving slots having a diameter largerthan the length of said tabs, the tabs in one of said panels beingreceived in the tab-receiving slots of the other, said tabs having anangled slot providing a wedging surface against the sheet materialsurrounding said tab-receiving slot, alternate ones of said tabs beinginclined inwardly and outwardly.
 2. The invention as defined in claim 1and a seal between adjacent panels, said seal including a resilient pad.3. The invention as defined in claim 2 wherein said resilient pad ismounted on a T-flange, said pad being mounted on the leg of saidT-flange, said leg being positioned in the butt joint between saidpanels, the head of said T-flange covering said joint.
 4. The inventionas defined in claim 3 wherein first and second resilient pads aremounted on first and second T-flanges, one of said T-flanges beingpositioned with its head covering the inner side of said joint, the headof the other of said T-flanges covering the outer side of said joint. 5.A wall for a modular building construction comprising: a panel includinga frame constructed of interconnected top, bottom and side members ofrigid sheet material, the opening in said frame being closed by innerand outer panel sheets, one of the sides of said frame having aplurality of aligned vertically spaced laterally projecting tabs, theother of the sides of said frame having a like plurality of similarlyspaced circular tab-receiving slots; first and second vertical columnsfor supporting said wall panel, said columns being constructed of sheetmaterial, one of said columns having a plurality of tab-receiving slotsfor receiving the tabs on said one side member, the other of saidcolumns having a plurality of tabs, said tabs being received in theslots in said other side member, said tab-receiving slots having adiameter larger than the length of said tab, said tab having an angledslot providing a wedging surface against the sheet material surroundingsaid tab-receiving slot, alternate ones of said tabs being inclinedinwardly and outwardly.
 6. The invention as defined in claim 5 whereineach of said columns comprises a cylindrical tube enclosed by aplurality of intermediate flat layers of rigid fireproofing material andan outer layer of rigid sheet metal, said layers providing a squareouter cross section.
 7. The invention as defined in claim 6 and a lowerhorizontal support for said wall, said support having spaced upstandingcylindrical pins, said cylindrical pins projecting into said cylindricaltubes of said columns for supporting and positioning the lower end ofsaid column.
 8. A wall for a modular building construction comprising: apanel including a frame constructed of interconnected top, bottom andside members of rigid sheet material, the opening in said frame beingclosed by inneR and outer panel sheets, said top and bottom members ofsaid frame each having a plurality of aligned laterally spacedpin-receiving holes, one of the sides of said frame having a pluralityof aligned vertically spaced laterally projecting tabs, the other of thesides of said frame having a like plurality of similarly spaced circulartab-receiving slots; a lower support for said wall, said lower supporthaving a plurality of upwardly extending pins projecting through saidpin-receiving holes in said bottom member; an upper support for saidwall, said upper support having a plurality of downwardly extending pinsprojecting into said pin-receiving holes in said top member; and firstand second columns constructed of sheet material, interconnectionsbetween said columns and said lower and upper supports, one of saidcolumns having a plurality of circular tab-receiving slots for receivingthe tabs on said one side member, the other of said columns having aplurality of tabs, said tabs being received in the slots in said otherside member, said circular slots having a diameter larger than thelength of said tabs, said tabs having an angled slot providing a wedgingsurface against the sheet material surrounding said tab-receiving slot,alternate ones of said tabs being inclined inwardly and outwardly. 9.The invention as defined in claim 8 wherein each of said columnscomprises a cylindrical tube enclosed by a plurality of intermediateflat layers of rigid fireproofing material and an outer layer of rigidsheet metal to provide a square outer cross section, said tabs andtab-receiving slots being located on said outer layers of respectivecolumns.
 10. The invention as defined in claim 9, the interconnectionbetween each column and said lower support for said wall includes anupstanding cylindrical pin secured on said support, said cylindrical pinprojecting into the cylindrical tube of said column, each of said pinsproviding a predetermined position for each of said columns on saidsupport.
 11. The combination comprising: two abutting sheet metalsurfaces; a plurality of spaced aligned tabs projecting from one of saidsurfaces; a like plurality of tab-receiving circular slots in the othersurface, said slots having a diameter greater than the length of saidtab, said tabs projecting through said slots, said tabs having an angledwedging surface providing a wedge between said tabs and the surfacesurrounding said slots, adjacent tabs being oppositely inclined wherebysaid surfaces are firmly interconnected.
 12. A wall for a modularbuilding construction comprising: a panel including a frame constructedof interconnected top, bottom and side members of rigid sheet material,the opening in said frame being closed by inner and outer panel sheets,said top and bottom members of said frame each having a plurality ofaligned laterally spaced pin-receiving holes; a lower support for saidwall, said lower support having a plurality of upwardly extending pinsprojecting through said pin-receiving holes in said bottom member; anupper support for said wall, said upper support having a plurality ofdownwardly extending pins projecting into said pin-receiving holes insaid top member; first and second columns constructed of sheet material;interconnections between said columns and said lower and upper supportsand between said columns and the sides of said frame, each of saidcolumns comprising a cylindrical tube enclosed by a plurality ofintermediate flat layers of rigid fireproofing material and an outerlayer of rigid sheet metal to provide a square outer cross section, theinterconnection between each column and said lower support for said wallcomprising an upstanding cylindrical pin secured on said support, saidcylindrical pin projecting into the cylindrical tube of said column,each of said pins providing a predetermined position for each of saidcolumns on said support, the interconnection between each column and thesIdes of said panel being between a side member of said panel and saidouter layer.
 13. A wall for a modular building construction comprising:a panel including a frame constructed of interconnected top, bottom andside members of rigid sheet material, the opening in said frame beingclosed by inner and outer panel sheets, said top and bottom members ofsaid frame each having a plurality of aligned laterally spacedpin-receiving holes; a lower support for said wall, said lower supporthaving a plurality of upwardly extending pins projecting through saidpin-receiving holes in said bottom member; an upper support for saidwall, said upper support having a plurality of downwardly extending pinsprojecting into said pin-receiving holes in said top member; first andsecond columns; interconnections between said columns and said lower andupper supports and between said columns and the sides of said frame,each of said columns having a square outer cross section, theinterconnection between each column and said lower support for said wallcomprising an upstanding pin secured on said support, said pinprojecting into said column, each of said pins providing a predeterminedposition for each of said columns on said support.